Method of wrapping elongate cylindrical objects

ABSTRACT

The cylindrical object is covered with a strip of sheet material having a width less than the length of the object and is applied by rotating the object while feeding the sheet material at a right angle to the rotational axis of the object to provide convolute windings around opposite end portions of the object and guiding the sheet material in angular relationship to the rotational axis of the object to provide spiral windings around the medial portion of the object. A pair of rolls support and rotate the object while the sheet material is fed from a carriage which moves along a path of travel parallel to the drive rolls and the angular position of the carriage is varied to thereby change the relationship between the rotational axis of the supply roll and the rotational axis of the object so as to permit both convolute and spiral windings to be applied to the object.

United States Edwards et al.

atent 1 51 Dec. 30, 1975 METHOD OF WRAPPING ELONGATE CYLINDRICAL OBJECTS[73] Assignee: John Edwards & Associates, Inc., Charlotte, N.C.

221 Filed: On. 29, 1974 21 Appl.No.:5118,995

Related US. Application Data [62] Division of Ser. No. 360,156, May 14,1973, Pat. No.

1/1974 Sato 93/80 12/1974 Klebanoff, Jr. 53/32 X Primary ExaminerTravisS. McGehee Assistant Examiner-John Sipos Attorney, Agent, orFirm-Parrott, Bell, Seltzer, Park & Gibson [57] ABSTRACT The cylindricalobject is covered with a strip of sheet material having a width lessthan the length of the object and is applied by rotating the objectwhile feeding the sheet material at a right angle to the rotational axisof the object to provide convolute windings around opposite end portionsof the object and guiding the sheet material in angular relationship tothe rotational axis of the object to provide spiral windings around themedial portion of the object. A pair of rolls support and rotate theobject while the sheet material is fed from a carriage which moves alonga path of travel parallel to the drive rolls and the angular position ofthe carriage is varied to thereby change the relationship between therotational axis of the supply roll and the rotational axis of the objectso as to permit both convolute and spiral windings to be applied to theob- 7 Claims, 14 Drawing Figures 52 us. Cl 53/32; 93/80 [51] Int. Cl.B65B 11/04 [58] Field of Search 53/32, 33, 210, 211;

[56] References Cited UNITED STATES PATENTS 2,716,315 8/1955 Jacoby93/80 X 2,878,628 3/1959 Curry 53/30 S 3,191,289 6/1965 Fleischer 93/80X 3,412,524 11/1968 Nestell 53/212 ject. 3,549,077 12/1970 Huck 93/80 X3,708,132 1/1973 Lang 242/723 US. Patent Dec. 30, 1975 Sheet 1 of33,928,939

US. Patent Dec. 30, 1975 Sheet20f3 3,928,939

US. Patent Dec. 30, 1975 Sheet3of3 3,928,939

METHOD OF WRAPPING ELONGATE CYLINDRICAL OBJECTS This is a division ofapplication Ser. No. 360,156,

filed May 14, 1973 now US. Pat. No. 3,863,425.

This invention relates generally to a method of wrapping elongateobjects and more particularly to the application of both convolute andspiral wrappings to cylindrical objects with elongate sheet materialhaving 1 a width less than the length of the object.

Most elongate objects, such as rolls of carpet, woven and knittedfabricand the like are presently covered with convolute windings ofpaper or with a single covering of thermoplastic film which encloses theobject and is heat sealed along one side and at opposite ends. Apparatusfor covering elongate objects which is presently available uses aparticular width of paper or film in covering elongate objects of aparticular diameter and length. Thus, a different width of paper or filmmust be used for each different length of cylindrical object to becovered.

With the foregoing in mind, it is an object of the present invention toprovide a method of wrapping cylindrical objects which permits the useof a strip of sheet material of a particular width in wrapping a largerange of different size cylindrical objects having various diameters andlengths.

In accordance with the present invention, elongate sheet material havinga width less than the length of the object is fed to the rotating objectto form convolute windings around opposite end portions and to formspiral windings around the medial portion of the object. A pair ofspaced apart rolls support and rotate the object while the sheetmaterial is withdrawn from a supply roll supported on a carriage whichis moved along a path of travel parallel to the cylindrical object. Theangular position of the carriage and the supply roll is controlled tovary the angular relationship between the rotational axis of the supplyroll and the rotational axis of the object being covered so thatconvolute windings and spiral windings may be selectively applied to theobject being wrapped. The sheet material preferably used is in the formof a heat shrinkable and heat settable film so that the wrappedcylindrical object may be moved into a heat tunnel and the wrappingmaterial will shrink into tight engagement with the object and theoverlapping portions of the windings are heat sealed together to form apackage completely enclosing and protecting the cylindrical object frommoisture, dirt and the like. The completed package provides adequateprotection of the cylindrical object during handling, shipping, storageand the like.

Other objects and advantages will appear as the description proceedswhen taken in connection with the accompanying drawings, in which:

FIG. 1 is a perspective view of the wrapping apparatus and illustratinga portion of a heat shrinking and sealing tunnel positioned at one endof the wrapping apparatus for receiving the covered cylindrical object;

FIG. 2 is a plan view of the apparatus illustrated in FIG. 1;

FIG. 3 is a fragmentary end elevational view looking at the right-handend of the apparatus illustrated in FIG. 2 and with the supply rollcarriage being positioned at a right angle to the cylindrical object;

FIG. 4 is a fragmentary vertical sectional view through the supply rollcarriage and the drive rolls for the cylindrical object and illustratingthe sheet material being fed to and wound on the cylindrical object;

FIG. 5 is a fragmentary plan view, with parts broken away, of the supplyroll carriage and illustrating the support plate therefore;

FIG. 6 is an enlarged fragmentary elevational view taken substantiallyalong the line 66 in FIG. 5;

FIG. 7 is a fragmentary sectional view taken substantially along theline 7-7 in FIG. 6; 0

FIG. 8 is a longitudinal sectional view taken substantially along theline 88 in FIG. 2 and with the cylindrical object being removed;

FIGS. 9-11 are schematic plan views illustrating the movement of thecarriage during the successive steps carried out in wrapping acylindrical object;

FIG. 12 is another schematic view illustrating the movement of thecarriage when providing a double spiral wrap on the medial portion ofthe cylindrical object;

FIG. 13 is a transverse vertical sectional view taken substantiallyalong the line 13-13 in FIG. 8; and

FIG. 14 is another schematic view illustrating the manner in whichopposite side portions of the sheet material may be heated to shrink thesame and prevent accumulation of excess sheet material when beginningand completing the spiral wrapping of the medial portion of thecylindrical object.

The apparatus used in carrying out the method of the present inventionis particularly adapted for covering various types of elongatecylindrical objects and may utilize any type of elongate sheet materialhaving a width less than the length of the object to be wrapped. Thepresent apparatus will be described for use in wrapping rolls of textilematerial, such as carpet, knit and woven fabrics and the elongate sheetmaterial is preferably of the heat shrinkable and heat settable type ofthermoplastic film.

The apparatus includes an elongate A-frame, broadly indicated at 10,which is preferably supported on rollers 11 for ease of mobility. Asillustrated in FIG. 8, the frame 10 is formed of end frame members 12and 13 and intermediate frame members 14 spaced therebetween. An upperlongitudinal frame member 15 extends from one end frame to the other(FIGS. 4, 8 and 13) and supports the upper ends of the intermediateframes 14. End bearing blocks 16, 17 (FIG. 8) are fixed on the endframes 12, 13 and rotatably support opposite ends of a pair of driverolls 18, 19. As illustrated in FIGS. 3 and 4-, the distance between therolls 18, I9 is less than the diameter of the cylindrical object 20 tobe wrapped so that the object is supported between and on the rolls l8,19.

Means is provided for driving at least one of the rolls 18, 19 to impartrotation to object 20 while it is supported on the rolls and includes avariable speed electric drive motor 21 (FIG. 13) which is drivinglyconnected by a drive belt 22 to a first jack shaft 23. A drive belt 24imparts rotation from the jack shaft 23 to a second jack shaft 25. Drivebelts 26 and 27 impart rotation from the jack shafts 23, 25 to the rollsl8, l9. Conveyor means is supported between the pair of rolls 18, 19 andincludes a longitudinally extending channel frame 30 rotatablysupporting a plurality of spaced apart conveyor rollers 31.

Means is provided for moving the conveyor rollers 31 between a raised oroperative position, as shown in dotted lines in FIG. 4, where thecylindrical object 20 is maintained out of engagement with the driverolls l8,

19 so that the cylindrical object may be moved in a longitudinaldirection, and a lowered inoperative position, as shown in solid linesin FIG. 4, where the cylindrical object is supported between and on thepair of rolls 18, 19. The conveyor raising and lowering means includesspaced apart air cylinders 32 (FIG. 8) which are supported on thelongitudinal frame member and have upwardly extending piston rods 32awhich are fixed at their upper ends to the channel frame 30. Air supplylines are connected at one end to each of the air cylinders 32 and theirother ends are connected to a main air supply manifold 33 (FIG. 1) whichenters one end of the end frame 12 and extends along the length of theframe 10. Air under pressure is supplied to the manifold 33 through anair supply line 34 extending from any suitable source of air pressure,not shown.

When the conveyor rollers 31 are raised to the dotted line positionshown in FIG. 4, the cylindrical object may be moved longitudinally intothe proper position between and spaced above the rolls 18, 19. Theconveyor rollers 31 are then lowered so that the cylindrical object issupported between and on the rolls l8, 19. After the wrapping operationis completed, the conveyor rollers 31 may be again raised and thecovered cylindrical object can then be easily moved longitudinally abovethe rolls l8, l9 and into a conventional type of heat tunnel, indicatedat in FIG. 1. There are any number of different types of heat tunnelswhich may be employed for supplying sufficient heat to shrink thewrapping and to seal the overlapping portion of the wrapping together soas to form a tight package completely enclosing the cylindrical object.The heat tunnel 40 illustrated in FIG. 1 includes a conveyor 41 whichmoves the object into and through the heat tunnel 40.

Carriage means is provided for supporting a supply roll 42 of elongatesheet material. This sheet material is preferably in the form of athermoplastic film, indicated at F. It has been found that a film whichis 30 inches wide will satisfactorily cover most lengths and diametersof rolled material. The carriage means includes a pivot plate 45 whichis pivoted intermediate its ends by a pivot pin 46 and is supported forpivotal swinging movement on a semicircular support plate 47 (FIG. 5).Upstanding end walls 50, 51 are provided at opposite ends of the pivotplate 45 and rotatably support a pair of rubber covered rolls 52, 53which rotatably support the film supply roll 42. Adjustable spacercollars 54, 55 (FIG. 2) are fixed on the rubber covered roll 52 andmaintain the supply roll 42 in the proper position.

The film F is guided from the supply roll 42 and passes between a pairof nip rolls 56, 57 (FIG. 4) which are rotatably supported at oppositeends in the end walls 50, 51. An electromagnetic brake 60 is provided onthe end of the upper nip roll 56 (FIG. 5) so that the amount of pressurerequired to withdraw the film from the supply roll 42' may be varied andto thereby wrap the film about the object with the desired degree oftension. A suitable control is provided on a control panel 61 forvarying the amount of braking action applied by the electromagneticclutch 60.

Film cutting means in the form of a heated electrical resistance wire 63is supported at opposite ends in support arms 64, 65 which are attachedat their lower ends to a control shaft 66 (FIG. 4). The control shaft 66is supported for oscillation in bearings on the end plates 50, 51 andthe upper end of a control arm 70 is fixed to a medial portion thereof.The end of the piston rod of a pneumatic cylinder 72 is connected to thelower end of the control arm 70 and the operation of the cylinder 72 iscontrolled by a suitable control on the control panel 61. A U-shapedchannel 74 (FIG. 4) is supported beneath the film F so that when theheated electrical resistance wire 63 is lowered, the wire will passthrough and sever the film F.

Drive means is provided for moving the carriage along a path of travelparallel to the pair of rolls 18, 19 and includes pairs of spaced apartbearings 75, 76 (FIGS. 3 and 4) which are fixed to the lower surface ofthe support plate 47 and ride on spaced apart tracks in the form of rods77, 78. The track rods 77, 78 are supported in spaced relationship onsupport brackets 80 which are in turn fixed on channel members 81, 82. Areversible and variable speed electric drive motor 83 is supportedbetween the track rods 77, 78 and includes a drive sprocket 84 which isengaged by a drive chain 85. Opposite ends of the drive chain 85 arefixed to the lower surface of the support plate 47 and a sprocket 86 isrotatably supported at the left-hand end of the wrapping apparatus (FIG.2) and engages the drive chain 85. As the direction and speed of thereversible electric motor 83 is controlled from the control panel 61,the support plate 47 and the film supply roll support carriage is movedalong the track rods 77, 78 and parallel to the cylindrical object beingwrapped.

Control means is provided for varying the angular position of thecarriage and the pivot plate 45 to thereby change the angularrelationship between the rotational axis of the supply roll 42 and therotational axis of the object 20 being wrapped so that at timesconvolute windings may be formed as schematically illustrated in FIGS. 9and 11, and at other times spiral windings may be formed, asschematically illustrated in FIGS. 10 and 12. The control means includesa series of circularly arranged holes 90 which are formed in the supportplate 47 and a drive gear 91 engaging the holes 90 and being driven by areversible electric motor 92 which is controlled from a suitable controlon the control panel 61. Thus, by rotating the gear 91 the pivot plate45 may be moved in either direction from that shown in FIG. 5, relativeto the support plate 47.

The support plate 47 is preferably semicircular, as illustrated in FIG.5, and the outer edge portion is provided with a bearing surface formedby a raised rim or ridge 89 of a friction reducing material forsupporting the pivot plate 45 as it is pivoted from one position toanother. Limit switches 93, 94 are supported on the support plate 47(FIG. 5) and are engaged by the pivot plate 45 as it moves to theextreme limits in either direction so that the pivot plate 45 may not bemoved beyond a predetermined position. Also, it is preferred that limitswitches 95, 96 (FIG. 2) be provided adjacent opposite ends of the trackrods 77, 78 so that the support plate 47 will engage these switches andprevent movement beyond these positions.

As a safety feature, a light beam producing head 100 is supportedadjacent the end frame 13 and an electric eye element 101 is supportedon the rear portion of the control panel 61 (FIG. 2). This safetyfeature is provided so that the apparatus will stop operating should theoperator or some other object move too close to the drive roll 19. Inthis event, the light beam will be broken and the machine will stop.

As is schematically illustrated in FIG. 14, means is provided forselectively heating opposite side portions of the film F, for purposesto be presently described.

This film heating means is illustrated as heated air blowers 105, 106which are suitably supported on the end plates 50, 51 of the supply rollsupport carriage.

METHOD OF OPERATION As schematically illustrated in FIG. 9, thecylindrical object 20 to be wrapped is placed in the proper position onthe pair of drive rolls 18, 19 and the film F is fed beneath and aroundthe object 20 while it is rotated. The carriage is maintained in astationary position to guide the film at a right angle to the rotationalaxis of the object and to provide at least one convolute winding aroundthis one end portion of the object. As the carriage begins to move in apath of travel parallel with the object 20, as illustrated in FIG. 10,the angular position of the carriage is changed so that the film isguided in angular relationship to the rotational axis of the object toprovide spiral windings around the medial portion of the object.

When the spiral windings have been completed to the opposite end of theobject, as illustrated in FIG. 1'1, parallel movement of the carriage isterminated and the carriage is again moved back to a position with thesupply roll at a right angle to the rotating object being wrapped toprovide one or more convolute windings around this other end portion ofthe object. The film is then cut by actuating the cylinder 72 to lowerthe heat resistance wire 63. The portions of the film extending overopposite ends of the object 20 are folded inwardly and the conveyorrollers 31 are raised so that the covered object may then belongitudinally moved into the heat shrinking tunnel 40 to complete theshrinking of the film and the heat sealing of the overlapping portionsof the wrapped package.

If it is desired to provide a double spiral wrap on the medial portionof the package, the pivot plate 45 will be merely rotated to theposition shown in FIG. 12 and the carriage will be moved back down thetrack rods 77, 78 so that spiral windings will be formed in a reversedirection from the direction of the initial spiral windings, asillustrated in FIG. 10, and the second spiral windings are formed overthe first spiral windings. The carriage will then be moved back to theposition shown in FIG. 9 to form one or more convolute windings at thisend of the object before the film is cut.

Also, varying degrees of coverage of the object may be obtained byvarying the speed of travel of the carriage and the angle at which thefilm is fed to the rotating object. Multiple or substantially singlefilm layers may be provided by feeding the film at selected anglesrelative to the axis of rotation of the object.

When changing from a convolute winding to a spiral winding and whenchanging from the spiral winding to the convolute winding, asillustrated in FIGS. 941, there is a tendency for excess film to beformed on one side portion and to be wrapped around the package. Thefilm shrinking heaters 105, 106 illustrated in FIG. 14 are provided toreduce or eliminate this excess film. As the carriage changes from thestraight position shown in FIG. 9 to the angular position shown in FIG.10, the heater 106 will be turned on to direct heated air onto theleft-hand side edge portion of the film and shrink the same, therebypreventing excess film from being wound onto the package. As thecarriage moves from the angular position shown in FIG. to the straightposition shown in FIG. 11, the heater 105 will be turned on to shrinkthe right-hand side edge portion of the film, thereby preventing excessfilm from being 6 wound onto the package. The air heater 105, 106 may beindividually controlled from the control panel 61 or they may beconnected to the circuit of the reversible drive motor 92 to operateautomatically with pivoting movement of the pivot plate 45.

In the drawings and specification, there has been set forth a preferredembodiment of the invention, and although specific terms are employed,they are used in a generic and descriptive sense only and not forpurposes of limitation. i I

We claim:

1. A method of covering a cylindrical object with elongate sheetmaterial having a width less than the length of said object, said methodcomprising steps of a. rotating said object,

b. withdrawing the elongate sheet material from a rotatable supply rolland wrapping it around one end portion of said object while maintainingthe rotational axis of the sheet material supply roll parallel to therotational axis of said object to provide at least one convolute windingaround said one end portion of said object,

. continuing to withdraw the elongate sheet material from the supplyroll and wrapping it around the medial portion of said object whilemoving the sheet material supply roll parallel to said object and withthe rotational axis of the supply roll in angular relationship to therotational axis of said object to provide spiral windings around saidmedial portion of said object, and

d. continuing to withdraw the elongate sheet material from the supplyroll and wrapping it around the other end portion of said object whilemaintaining the rotational axis of the sheet material supply rollparallel to the rotational axis of said object to provide at least oneconvolute winding around said other end portion of said object.

2. A method according to claim 1 wherein the elongate sheet material isheat scalable, and including the 0 step of heating the coveredcylindrical object to seal together the overlapping portions of thesheet material.

3. A method according to claim 2 wherein the sheet material is also heatshrinkable, and wherein the sheet material shrinks into tight engagementwith the cylindrical object during the heating step.

4. A method according to claim 1 wherein the convolute windings aroundopposite end portions of said object extend outwardly beyond the opposedends of said object, and including the step of folding the outwardlyextending portions of said convolute windings over the ends of saidobject to complete a package enclosing said object.

5. A method according to claim 4 wherein the sheet material is heatscalable and heat shrinkable, and including the step of heating thecovered cylindrical object to shrink the sheet material into tightcontact with said object to seal together the overlying portions of thesheet material and to seal the opposed ends folded inwardly over theends of said object to complete a package completely enclosing andprotecting said ob- 'ect.

J 6. A method according to claim 1 wherein said elon gate sheet materialis heat shrinkable, and including the step of heating one side edgeportion of the heat shrinkable sheet material at the beginning of thespiral wrapping of the medial portion of said object, and heating theopposite side edge portion of the heat shrinkable sheet material at thecompletion of the spiral wrapping relationship to the angularrelationship of the spiral winding applied in step (c) to provide secondspiral windings around the medial portion of said cylindrical object,and continuing to withdraw the elongate sheet material from the supplyroll and wrapping it around said one end portion of said object whilemaintaining the rotational axis of the sheet material supply rollparallel to the rotational axis of said object to provide at least oneadditional convolute winding around said one end portion and over theconvolute winding formed in step (b) to provide a double convolutewinding around said one end portion of said object.

1. A method of covering a cylindrical object with elongate sheeTmaterial having a width less than the length of said object, said methodcomprising steps of a. rotating said object, b. withdrawing the elongatesheet material from a rotatable supply roll and wrapping it around oneend portion of said object while maintaining the rotational axis of thesheet material supply roll parallel to the rotational axis of saidobject to provide at least one convolute winding around said one endportion of said object, c. continuing to withdraw the elongate sheetmaterial from the supply roll and wrapping it around the medial portionof said object while moving the sheet material supply roll parallel tosaid object and with the rotational axis of the supply roll in angularrelationship to the rotational axis of said object to provide spiralwindings around said medial portion of said object, and d. continuing towithdraw the elongate sheet material from the supply roll and wrappingit around the other end portion of said object while maintaining therotational axis of the sheet material supply roll parallel to therotational axis of said object to provide at least one convolute windingaround said other end portion of said object.
 2. A method according toclaim 1 wherein the elongate sheet material is heat sealable, andincluding the step of heating the covered cylindrical object to sealtogether the overlapping portions of the sheet material.
 3. A methodaccording to claim 2 wherein the sheet material is also heat shrinkable,and wherein the sheet material shrinks into tight engagement with thecylindrical object during the heating step.
 4. A method according toclaim 1 wherein the convolute windings around opposite end portions ofsaid object extend outwardly beyond the opposed ends of said object, andincluding the step of folding the outwardly extending portions of saidconvolute windings over the ends of said object to complete a packageenclosing said object.
 5. A method according to claim 4 wherein thesheet material is heat sealable and heat shrinkable, and including thestep of heating the covered cylindrical object to shrink the sheetmaterial into tight contact with said object to seal together theoverlying portions of the sheet material and to seal the opposed endsfolded inwardly over the ends of said object to complete a packagecompletely enclosing and protecting said object.
 6. A method accordingto claim 1 wherein said elongate sheet material is heat shrinkable, andincluding the step of heating one side edge portion of the heatshrinkable sheet material at the beginning of the spiral wrapping of themedial portion of said object, and heating the opposite side edgeportion of the heat shrinkable sheet material at the completion of thespiral wrapping of the medial portion of said object to prevent theaccumulation of excess sheet material around said object.
 7. A methodaccording to claim 1 including the further steps of continuing towithdraw the elongate sheet material from the supply roll and wrappingit around the medial portion of said object while moving sheet materialsupply roll parallel to said object and with the rotational axis of thesupply roll in an opposite angular relationship to the angularrelationship of the spiral winding applied in step (c) to provide secondspiral windings around the medial portion of said cylindrical object,and continuing to withdraw the elongate sheet material from the supplyroll and wrapping it around said one end portion of said object whilemaintaining the rotational axis of the sheet material supply rollparallel to the rotational axis of said object to provide at least oneadditional convolute winding around said one end portion and over theconvolute winding formed in step (b) to provide a double convolutewinding around said one end portion of said object.